Cardable fiber blend and a moldable fiber batt and the process for making a moldable fiber batt

ABSTRACT

The present invention provides a cardable fiber blend which forms a moldable fiber batt, the blend comprising fibers having a modulus of 550 g/denier or more with fibers of a thermoplastic polymer wherein the high modulus polymer fibers are all uncrimped fibers or a mixture of crimped and uncrimped fibers. The moldable batt is useful in making speaker cones.

BACKGROUND OF INVENTION

[0001] Methods for forming fiber batts require the use crimped fibersbecause uncrimped fibers are very difficult if not impossible to processthrough textile equipment. In some applications such as speaker cones,high modulus fibers are used in making the cone because these fibersstiffen and improve sound reproduction. Before the present invention, itwas necessary to crimp these high modulus fibers before they could beprocessed to form batts or felts. In the crimping process these stifffibers are broken and damaged. Fiber is also lost or wasted contributingto an increased in cost for such crimped fibers. Even if no fiber werelost or damaged in crimping, the need for this step, alone, adds bothprocessing time and costs in the production of batts and the productsmade from these batts.

[0002] Speaker cones are generally made from a paper or from a felt.Papers are non-woven webs produced by a wet lay process on papermachines, while non-woven felts are produced from fiber batts that areneedled together.

[0003] U.S. Pat. No. 4,112,168 teaches a speaker cone produced byimpregnating a fiber web with a resin solution, evaporating the solventto produce a non-woven fabric and then simultaneously laminating to thisfabric a gas tight film while molding the fabric into the speaker cone.

[0004] In another patent, U.S. Pat. No. 4,359,132, a speaker cone isproduced by forming a needled felt from ptextile fibers andpolypropylene textile fibers. Textile fibers are crimped fibers thatallow easy processing through textile equipment.

[0005] British Patent 2 037 122 B teaches a speaker cone made of a paperformed on a paper machine from stiff fibers such as p-aramid or carbonfibers.

[0006] An object of the present invention is to provide a easilymoldable batt using uncrimped high modulus polymer fibers. Such a batmay be molded into high quality speaker cones.

[0007] Another object in the present invention is to provide a cardablefiber blend from which the moldable batt may be formed.

[0008] Another object of the present invention is to provide a processfor producing a fiber batt that does not require crimped high modulusfiber.

[0009] Another object of the present invention is to provide a highquality speaker cone and a process for making this speaker cone.

SUMMARY OF INVENTION

[0010] The present invention provides an intimate, cardable blendcomprising crimped thermoplastic fibers and uncrimped high moduluspolymer fibers. It is preferred that the thermoplastic fibers arepolyolefin fibers and that the high modulus fibers have a modulus of atleast 550 g/denier. It is also preferred that the high modulus fibersare selected from the group consisting of p-aramid, aromatic polyesterfibers.

[0011] A second embodiment of the present invention is a batt formedfrom this intimate, cardable blend of fibers.

[0012] The present invention also provides a process for forming a fiberbatt comprising the steps of:(a) blending together uncrimped highmodulus polymer fibers having a modulus of 550 g/denier or more withfibers of a thermoplastic,(b) passing the blend through a device to openthe fibers, and(c) forming the fibers into a batt.

[0013] In this process it is preferred that the high modulus polymerfibers are selected from the group consisting of p-aramid and aromaticpolyester fibers.

[0014] In particular it is preferred that the crimped thermoplasticfibers are polyolefin or polyester fibers. For the high modulus polymerfibers, fibers that have a modulus greater than 750 g/denier areparticularly preferred. It is also preferred that the batt formed in thepresent process contains from about 30% to about 70% by weight of highmodulus polymer fibers and from about 70% to about 30% by weight crimpedthermoplastic fibers.

[0015] The present process can be used to produce a molded fiber productwhen after step (c), the batt is molded in a high temperature, highpressure mold. The batt formed by the present process is particularlysuited to be molded to form a speaker cone.

[0016] The batt and the molded product made from this batt may be thenatural color of the polymer fibers or may be colored to a desired hueand shade by selecting the fibers from the group consisting of naturalcolored thermoplastic polymer fibers, natural colored high moduluspolymer fibers, colored thermoplastic polymer fibers and colored highmodulus polymer fibers.

[0017] The present invention also provides an improved process forforming a speaker cone comprising the steps of:(a) blending togetherhigh modulus polymer fibers having a modulus of 550 g/denier or morewith fibers of a thermoplastic polymer,(b) passing the blend through adevice to open the fibers, (c) forming the fibers into a batt,(d)heating a mold to about 200° F. and placing the batt in the mold to forma speaker cone,(e) applying a pressure of from 5 to 20 tons to the moldand heating the mold to about 380° F., (f) allowing the mold to cool toabout 200° F. before opening the mold to remove the speaker cone.

[0018] In this improved process, it is desirable that the high moduluspolymer fibers are selected from the group consisting of p-aramid andaromatic polyester fibers and that the crimped thermoplastic fibers arepolyolefin or polyester fibers. High modulus fibers having a modulus ofat least 750 g/denier are particularly preferred. It is also desirablethat the batt formed contains from about 30% to about 70% by weight ofhigh modulus polymer fibers and from about 70% to about 30% by weightcrimped thermoplastic fibers. Also in this process during molding thebatt, a polyolefin film can be laminated to at least one face of thebatt. The term polyolefin film as used herein also includes fibrous thinlayers such as webs or batts and other terms used to describe thinlayers of polyethylene. For speaker cones it is particularly desirablethat the high modulus fibers are all uncrimped p-aramid fibers and thethermoplastic fiber is polypropylene.

[0019] The present invention provides a moldable fiber batt comprisingfibers having a modulus of 550 g/denier or more with fibers of athermoplastic polymer wherein the high modulus polymer fibers are alluncrimped fibers or a mixture of crimped and uncrimped fibers. It ispreferable that the high modulus fibers are selected from the groupconsisting of p-aramid, and fibers and that the crimped thermoplasticfibers are polyolefin or polyester fibers or a mixture of these fibers.Polymer fibers having a modulus greater than 750 g/denier areparticularly preferred for use as the high modulus fiber. It isparticularly desirable that the high modulus polymer fibers are alluncrimped p-aramid fibers and the thermoplastic polymer fibers are polypropylene.

DETAILED DESCRIPTION

[0020] The present invention provides an intimate, cardable fiber blendthat may be formed into a batt. This fiber batt is particularly usefulin making speaker cones.

[0021] As used herein, the term high modulus polymer fiber means a fiberthat has a modulus of 550 g/denier or more. High modulus polymer fibersthat are particular useful in the present invention include p-aramid andaromatic polyester fibers. Such fibers having a modulus of 750 g/denieror more are particularly preferred. In processing the uncrimped highmodulus fibers, the rate of carding may be increased by mixing into theuncrimped high modulus fiber an amount of crimped high modulus fiber.

[0022] When speaker cones are the desired product, it is recommendedthat the amount of crimped high modulus fiber present in a mixture withuncrimped high modulus fiber be less than 50% of the total weight of themixture of crimped and uncrimped high modulus fiber.

[0023] It is believed that the use of uncrimped high modulus fiber is ofparticular advantage for speaker cones. The presence of uncrimped highmodulus fiber produces a cone that, at least when rated subjectively,produces an improved sound reproduction, particularly of the humanvoice. Thus it is most desirable to use all uncrimped high modulusfiber. The mixing of crimped and uncrimped high modulus fiber asdescribed above allows one to balance sound reproduction quality andrate of carding while realizing benefits from the use of uncrimped highmodulus fiber in the cone.

[0024] The cardable fiber blend and the fiber batt of the presentinvention may be used for other purposes than making a speaker cone orother molded product. The batt itself may be used in insulation or forpadding.

[0025] Since the batt of the present invention contains thermoplasticpolymer fiber, the batt may be designed through polymer fiber selectionto be easily moldable over a range of temperatures, or to be stable overa range of temperatures. For a moldable fiber batt, polyolefin,polyester and polyphenylene sulfide fibers are useful.

[0026] Polypropylene fibers are most desirable for use in making speakercones.

[0027] The present invention provides a process for making a fiber battusing a blend of crimped and uncrimped fibers. Synthetic polymer fibersare crimped so that they process as natural fibers and can be processedto form batts, webs and fabrics using textile equipment. There is theadvantage of eliminating a process step, if uncrimped synthetic polymerfibers could be directly formed into a web or batt.

[0028] The inventor in the present invention has found that by combiningthermoplastic crimped polymer fibers and uncrimped high modulus polymerfibers, a combination of fibers is formed that can be processed bytextile equipment to form a batt or web. Even when a high concentrationof the uncrimped fiber is present, the fiber blend of the presentinvention can be processed using, for example, a Rando Webber or otherequipment for forming a web or batt.

[0029] In the present process the thermoplastic polymer fibers and thehigh modulus fibers are opened. Each fiber type may be opened separatelyand then combined to feed the webber or card, or the two types of fiberscan be first blended together, then opened and the opened blend is thenfed to the webber or card.

[0030] Card rates can be increased by using a mixture of uncrimped andcrimped high modulus fibers along with the thermoplastic polymer fibers.Generally for blends of the present invention, it is recommended thatthe amount of crimped high modulus fiber be present in an amount of notmore than 50% of the total weight of the mixture of crimped anduncrimped high modulus fiber.

[0031] The weight range preferred for batts for the present invention isfrom 0.5 to about 7 oz./yd². Batts may be made at a desired weight byforming that weight directly at the card or webber, or they may be madeby laminating lighter weight batts together to give the desired weight.This latter method is useful in molding speaker cones since singlethickness batts tend to wrinkle in the molding process. Also inproducing batts for molding, it is preferred that the batt be of lowdensity. To achieve a low density batt, it is preferred to produce thebatt using blower air-ducted or vacuum air duct process equipment, forexample, a Rando Webber.

[0032] In selecting fibers for the present process, it is preferred thatthe high modulus fibers are selected from the group consisting ofp-aramid, aromatic polyester, poly phenylene sulfide and aromaticpolyimide fibers and that the crimped thermoplastic fibers arepolyolefin or polyester fibers or a mixture of these fibers. It isparticularly desirable that the high modulus polymer fibers are alluncrimped p-aramid fibers and the thermoplastic polymer fibers arepolypropylene.

[0033] The batt of the present invention may be molded into desiredshapes if after step (c), the batt is molded in a high temperature, highpressure mold.

[0034] If one desires to mold speaker cones from the batts of thepresent invention, high quality speaker cones may be made using thefollowing improved process: (a) blending together high modulus polymerfibers having a modulus of 550 g/denier or more with fibers of athermoplastic polymer wherein the high modulus polymer fibers are alluncrimped fibers,(b) passing the blend through a device to open thefibers, (c) forming the fibers into a batt,(d) heating a mold to about200° F. and placing the batt in the mold to form a speaker cone, (e)applying a pressure of from 5 to 20 tons to the mold and heating themold to about 380° F., (f) allowing the mold to cool to about 200° F.before opening the mold to remove the speaker cone.

[0035] In this improved process it is desirable that the high moduluspolymer fibers are selected from the group consisting of p-aramid,aromatic polyester, poly phenylene sulfide and aromatic polyimide fibersand that the crimped thermoplastic fibers are polyolefin or polyesterfibers or a mixture of these fibers. It is also desirable that the battformed contains from about 30% to about 70% by weight of high moduluspolymer fibers and from about 70% to about 30% by weight crimpedthermoplastic fibers. Also in this process during molding the batt apolyolefin film can be laminated to the batt. For speaker cones it isparticularly desirable that the high modulus fibers are all uncrimpedp-aramid fibers and the thermoplastic fiber is polypropylene.

[0036] In the molding process the speaker cone may be colored byselecting the fibers, both the thermoplastic polymer and the highmodulus fibers, from fibers either natural colored thermoplastic polymerfibers, natural colored high modulus polymer fibers, coloredthermoplastic polymer fibers and colored high modulus polymer fibers.Combinations of the natural colored p-aramid fiber, for example which isyellow with either colored or natural colored polypropylene fibers allsome latitude in formulation a desired hue and shade. A second method bywhich the speaker cones of the present invention may be colored is tolaminate a thin film of the thermoplastic polymer colored to the desiredhue and shade to the speaker cone surface during the molding step. Thissecond method of producing a color offers a wide possibility of both hueand shade in a speaker cone product.

[0037] The present invention is illustrated by the followingnon-limiting examples.

EXAMPLE 1

[0038] Uncrimped KEVLAR 49 brand poly p-phenylene terepthalamide fiberproduced by E. I. du Pont de Nemours and Company of Wilmington, Del.,and having a nominal tensile modulus 885 gms/denier, a nominal breakingtenacity 23.6 gms/denier in ¼″ cut length and a 1.5 denier was preopenedby using a vacuum air duct system. (KEVLAR is a trademark of E. I. duPont de Nemours and Company).

[0039] Crimped polypropylene fibers having a 1.5″ cut length and 1.5denier were pre-opened by passing them through the Rando Opener. Thesetwo fibers were blended in a ratio of 50/50 by weight using the vacuumair duct system. Blends were processed through the Rando Opener threetimes followed by running two times through the Rando Webber to producenon-woven batts. These webs were rolled using cellophane or paper as theliner. Batts of the following weights were produced 2.5, 3.5 and 4.5oz./yd². In several cases steam was used in the Rando Webber forimproved processing.

[0040] The webs or batts were then die cut or layered and die cut intopieces of about 6″ diameter for molding into cones. The desired mold wasinstalled into a high temperature press and heated using band heaters to380° F. The die cut sample was placed between the two halves of themolds, and the press was closed to a molding pressure of from 5 to 20tons. After about 20 seconds, the cold water was circulated to cool themold to about 150° F. The press was opened and the part removed.

[0041] These cones were assembled into speakers and compared with paperand polypropylene cones. In key listening tests, these cones providedsuperior acoustic performance particularly higher sensitivity and lowerdistortion than the controls.

EXAMPLE 2

[0042] Uncrimped KEVLAR 149 brand poly pterephthalamide fibers having atensile modulus 1000 gms/denier, breaking tenacity 21 gms/denier and cutlength ¼″ were blended with polypropylene fibers and formed into a battaccording to Example 1. These batts were also molded into cones.

[0043] The cones were yellow in color, because of the natural color ofK149 and the natural white color of the polypropylene fibers.

EXAMPLE 3

[0044] Uncrimped natural yellow color KEVLAR 149 brand fibers wereblended with black color polypropylene, resulting in a greenish colorbatt. This batt was molded into cones that have marble green look tothem.

EXAMPLE 4

[0045] The dark blue colored KEVLAR 49 brand fibers were blended withblack polypropylene fibers, resulting in a dark bluish black batt. Thisbatt, together with layers of black polypropylene placed on each face ofthe batt, were placed in the mold and processed. Darker colored coneswere produced.

EXAMPLE 5

[0046] A speaker cone was molded in the improved process of the presentinvention by heat the mold to 200° F., placing batt made according toExample 1 between the molds and closing the press and applying 10-20tons pressure. The mold was then heated to 380° F.; and after a holdtime of about 10 minutes, the mold was cooled down to about 200° F. Thepress was then opened and the cone removed. The quality and uniformityof this cone was very high because of intimate blending of polypropyleneand p-aramid fibers in the formation of the batt in this moldingprocess.

1. A process for forming a fiber batt comprising the steps of: (a)blending together high modulus polymer fibers having a modulus of 550g/denier or more with fibers of a thermoplastic polymer wherein the highmodulus polymer fibers are all uncrimped fibers or a mixture of crimpedand uncrimped fibers, (b) passing the blend through a device to open thefibers, and (c) forming the fibers into a batt.
 2. The process of claim1 wherein the high modulus polymer fibers are selected from the groupconsisting of p-aramid and aromatic polyester fibers.
 3. The process ofclaim 1 wherein the high modulus fibers have a modulus of 750 g/denieror more.
 4. The process of claim 1 wherein the crimped thermoplasticfibers are polyolefin or polyester fibers.
 5. The process of claim 1wherein the batt formed contains from about 30% to about 70% by weightof high modulus polymer fibers and from about 70% to about 30% by weightcrimped thermoplastic fibers.
 6. The process of claim 1 wherein in themixture of uncrimped and crimped high modulus fibers the crimped fiberrepresents less than about 50% by weight of the mixture.
 7. The processof claim 1 wherein after step (c), the batt is molded in a hightemperature, high pressure mold.
 8. The process of claim 7 wherein thefibers are selected from the group consisting of natural coloredthermoplastic polymer fibers, natural colored high modulus polymerfibers, colored thermoplastic polymer fibers and colored high moduluspolymer fibers.
 9. An improved process for forming a speaker conecomprising the steps of: (a) blending together high modulus polymerfibers having a modulus of 550 g/denier or more with fibers of athermoplastic polymer wherein the high modulus polymer fibers are alluncrimped fibers or a mixture of crimped and uncrimped fibers, (b)passing the blend through a device to open the fibers, (c) forming thefibers into a batt, (d) heating a mold to about 200° F. and placing thebatt in the mold to form a speaker cone, (e) applying a pressure of from5 to 20 tons to the mold and heating the mold to about 380° F., (f)allowing the mold to cool to about 200° F. before opening the mold toremove the speaker cone.
 10. The process of claim 9 wherein the highmodulus polymer fibers are selected from the group consisting ofp-aramid and aromatic polyester fibers.
 11. The process of claim 9wherein the crimped thermoplastic fibers are polyolefin or polyesterfibers.
 12. The process of claim 9 wherein the high modulus fiber has amodulus of 750 g/denier or more.
 13. The process of claim 9 wherein thebatt formed contains from about 30% to about 70% by weight of highmodulus polymer fibers and from about 70% to about 30% by weight crimpedthermoplastic fibers.
 14. The process of claim 9 wherein in the mixtureof uncrimped and crimped high modulus fibers, the crimped fiberrepresents less than about 50% by weight of the mixture.
 15. The processof claim 9 wherein the fibers are selected from the group consisting ofnatural colored thermoplastic polymer fibers, natural colored highmodulus polymer fibers, colored thermoplastic polymer fibers and coloredhigh modulus polymer fibers.
 16. The process of claims 1 or 9 whereinduring molding the batt a polyolefin film is laminated to at least onefacet of the batt.
 17. The process of claims 1 or 9 wherein the highmodulus fibers are all uncrimped p-aramid fibers and the thermoplasticfiber is polypropylene.